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TURBOTIGHT AND TURNKEY SOFTWARE BRING DYNAMICS AND PRECISION TO THE WEAKEST POINT IN PRODUCTION

 

Assembling modules at a car plant is very demanding and complicated. When it comes to safety, the models must meet stringent quality requirements. One crucial factor is reliably tightening a large number of joints. Thanks to modernization of a production line, to which Atlas Copco added a new control unit, the Mobis plant in Nošovice, Czech Republic, can create quality joints with great efficiency.

Mobis is the Hyundai Motor Company’s biggest supplier. At its Nošovice plant, it assembles a total of four modules: the front face, the front and rear axle, and the instrument panel. Modularization is one of the main trends in the automotive industry, and it is crucial to maintaining supplier competitiveness. However, it makes demands on the assembly process itself. Most modules are made up of many small parts that must be attached with a large number joints for correct operation and the safety of the crew.

“For example, when instrument panels are assembled, some of the assembly stations have room for only one operator. For an entire process with several operations,” notes Karel Tomeček, a production engineer at Mobis. He points to the necessity of installing a wiring harness on an internal reinforcement and grounding it, or installing the plastic part of a dashboard and attaching it to the brace. “In that case, the worker has to handle several complicated tasks in a very short time reflecting the pace of the production line,” Tomeček adds.

That is exactly why at the Mobis plant, the instrument panel line is the slowest point in the entire assembly. They were looking for a way to shorten the time needed for joint tightening as much as possible. “The pneumatic screwdrivers Mobis used in the plant did not offer the tightening speed needed. Besides that, they didn’t offer monitoring and control of the process,” explains Michal Kilián, an Atlas Copco representative, in regard to the situation on the line. Directly driven screwdriver models providing only a standard tightening strategy were also not ideal when it came to ergonomics, especially when reaction force increased during tightening.

For this reason, the customer turned to Atlas Copco with a request to transform their tool situation. “The technicians in Nošovice were interested in electric nutrunners that would be light, fast and display lower reaction force,” explains Kilián. To contribute to production modernization, monitoring of the tightening process was also requested.

“We recommended the ETP ES screwdriver with a pistol grip. It is made for demanding work environments like automotive module production,” says Kilián. A new motor design provides significantly faster speed than the screwdriver previously used. The revolutionary TurboTight strategy allows this high speed to be combined with the required precision and the ergonomics of the assembly process. “Its advantages also include less noise and less reaction force into the operator’s hand. Compared to the standard tightening strategy, it is also faster and easier to adjust,” he adds.

Combining the screwdriver with the Power Focus 6000 control unit allows traceability that precisely meets the customer’s requirements. To exact specifications, the Atlas Copco team developed for Mobis a special hardware key called Mobis IAM Multi-Control that can guide and trace screwdriver activity exactly as the customer requests.

Thanks to fast, smooth implementation of the Power Focus 6000 control unit, the Nošovice plant can now plug in other Atlas Copco electronically controlled tools anywhere in production. “The combination of Tensor ES nutrunners and the Power Focus 6000 control unit may inspire other automotive industry customers who have similar production problems and would like to decrease reaction force or the time needed to tighten joints,” Kilián believes

Power Focus 6000 range Power Focus 6000 range

 

 

 

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